IIW Commission XIV Workshop success: Showcasing

WELDING TRAINING SYSTEMS
IIW Commission XIV Workshop success:
Showcasing latest international
developments in welding training systems
A key objective in any country should be to improve the quality
of the everyday life of its people, and the optimisation of welding
activities can assist in meeting this objective. The use of the most
up-to-date education and training techniques to improve the
competence of people is one effective strategy. Improvements in
productivity, quality, cost reduction, health and safety are immediate
gains for companies and individuals, and thus a country as a whole
– whether a developed nation or an economy in transition.
S
ix world leaders in welding education
and training systems showcased their
latest developments to an international
audience during a workshop at the recent
Annual Assembly of the International
Institute of Welding (IIW) held in Korea
in July. Fifty-seven countries are members
of IIW, which has amongst its guiding
principles the sharing of knowledge to help
identify, create, develop and transfer the
best practices for sustainable development
in a sustainable environment.
Interested readers can get in touch
with the experts directly via the contact
details given below. WTIA is also disseminating information regarding the
systems throughout Australia to facilitate
assessment of their potential contributions
to welder education and training in this
country.
Welding education
and training systems
The Lincoln Electric VRTEX 360
The Lincoln Electric VRTEX 360 is a
virtual reality training system that enables
welders to be trained better, faster and
at lower cost. As an interactive welding simulator it uses a welding gun and
helmet connected to a CPU about the size
of small generator. The helmet includes
speakers and 3D goggles, through which
the trainee sees a virtual welding gun and
work site, such as a high-rise or welding
booth. Speakers in the helmet broadcast
the tell-tale pop and sizzle of materials
being melted and joined.
The IIW working unit Commission
XIV Education and training, under
the chairmanship of Australian Chris
Smallbone, hosted the workshop and the
attendees from around the world agreed
that the information gained would help
them plan future directions for innovative, cost effective welder education and
training in their countries.
The six systems summarised in the
article are being utilised by training bodies,
companies and organisations around the
world, and are continually evolving to meet
the needs of industry and educational best
practice in a wide range of socioeconomic
environments.
Training with the Lincoln VRTEX 360
Welder education and training system experts from left: Satoru Asai (Toshiba), Claude Choquet (123 Certification Inc),
Jan Neubert (SLV Halle), Chris Smallbone (WTIA), Basilio Marquinez (Seabery Soluciones), Carl Peters (Lincoln Electric),
Chris Conrardy (EWI/RealWeld), Jorge Huete (CESOL)
18 AUSTRALASIAN WELDING JOURNAL – VOLUME 59, THIRD QUARTER – 2014
The VRTEX® Mobile is the latest
development of the system. This is a
basic, entry level welding training system
designed to provide mobility in an easy to
use and engaging welding training tool. It
is ideal for initial, basic welding training,
as a recruitment and engagement tool for
educational and industry and for employment and screening for human resources
or as an evaluation tool for instructors
and educators to get a baseline on student knowledge. Rental schemes may be
available too, improving accessibility and
affordability of the system.
Carl Peters, Director of Training at Lincoln, noted that ‘Lincoln Electric worked
with Iowa State University to compare
traditional welding training with Virtual
Reality Integrated Weld Training. The
results clearly show that with a blend of
both types of training, costs and time are
significantly reduced, certification rates
are substantially higher, and there are a
greater number of welds performed using
virtual reality. Team learning and interaction levels are higher with virtual welding.’
Peters commented that ‘VRTEX®
Mobile could see application in the future
in developing countries where costs and
lack of training facilities are a real challenge. Exposure through IIW is highlighting the exciting potential uses of virtual
training in countries around the world’.
Contact: Carl Peters
Email: [email protected]
The VRTEX system is used widely in
training organisations, industry, and the
US military, and has been demonstrated
at trade exhibitions around the world.
It proved popular with competitors and
visitors alike at the 2011 London and
2013 Leipzig WorldSkills international
competitions and is featured in the AWS
Careers in Welding Trailer which travels
extensively in the US and Canada promoting welding.
Soldamatic Augmented Training
Soldamatic is an educational technology
for welding training which uses interactive simulation together with augmented
reality. It offers a wide range of features
including configuration to the different
weld processes, and in turn, to different
training courses – from the initial to the
most advanced levels.
Welding instructors themselves recognise that the traditional training methods,
though suitable in the past, can now be
inefficient. High costs of materials and
Soldamatic Augmented Training – not just a trainer-simulator for welding but a
comprehensive educational solution
consumables impact on effective time for
practice and insufficient qualified trainers
can reduce on-on-one training time. Coupled with the expense of equipment and
facilities, these may lead to the output of
personnel who are unable to meet industry
requirements.
Soldamatic Augmented Training is not
just a trainer-simulator for welding – it is
a comprehensive educational solution that
includes a full educational platform and
classroom network.
The system is not intended to modify
the contents of welding training courses,
but simply organise them in a different way
to obtain better assimilation of knowledge,
and provide a greater number of effective
practice experiences. It offers an incredibly
realistic environment where the student
follows the same steps and experiences
the same sensations as if he were at his
workplace, so the trainee will pass to the
workshop once he really achieves all the
necessary skills and knowledge.
The platform includes teacher software
for training management, cloud-based
blended learning capabilities, student simulators incorporating augmented reality,
and a module for analysis of the exercises
performed by the students. Networked
computers enable the teacher to monitor
each student simulator and to give personalised feedback whenever it is needed.
The advanced educational concept
of Soldamatic was explained by Basilio
Marquinez, CEO of Seabery Soluciones,
SL which developed the system in Spain.
The progressive learning model is based
on students’ skills and level of knowledge
instead of a rigid linear model based on
time. The system is also designed to fit
the course contents following the International Welder (IW) Guidelines from
EWF/IIW, and also the SENSE Program
from the AWS. It allows any teacher or
training body to upload their own training programs – or create new contents
- easily introducing Working Procedure
Specifications while configuring the
system to perform that way, or acquiring
full welding courses fitting with those
international standards.
With up to 180 systems already in service in over 25 countries, Marquinez highlighted the value of remote maintenance
and customer service which the company
provides in real time worldwide. The
website is also utilised to deliver customer
care to end users and distributors, while
applications for smartphones and tablets
appeal to younger generations and aid
in the recruitment of students to training
AUSTRALASIAN WELDING JOURNAL – VOLUME 59, THIRD QUARTER – 2014 19
WELDING TRAINING SYSTEMS
VRTEX 360 closely simulates a real
welding puddle so that the student learns
to weld very much like real welding. The
student uses visual and audible puddle
feedback to make the proper motion
changes in order to make defect free welds.
The system accurately scores the weld,
visually indicates proper versus improper
movements and indicates what welding
defects resulted from any improper techniques. Visual cues can be used to help
correct any improper techniques. Once a
weld is complete, the student can perform
a virtual bend test on the weld coupon.
WELDING TRAINING SYSTEMS
courses. Ongoing review and utilisation
of modern technologies and delivery
methods are helping to bring purchase
prices down and promoting uptake of the
Soldamatic Augmented Training system.
Contact: Basilio Marquinez
Email: [email protected]
123 Certification ARC®+
The Arc+ Welding Simulator is a training
tool that powers lifelike virtual welding practice. It is the most complete,
easy-to-use and realistic simulator on
the market. The simulator’s movement
detection system breaks down its user’s
manual dexterity parameters and trains
all welding positions without any need
for calibration. Its graphic interface and
use of real welding torches account for
its unequalled realism.
The ARC®+ system platform was first
introduced in Canada through companies
and welding schools and has now been
sold in more than 20 countries around
the world.
Organisations utilising Arc+ range
from high schools to universities and
training authorities, all the way to private
companies that use the simulators for their
in-house training program. One customer, Jean-Pierre Lupien of
the Tremblay Group involved in construction and steel structure manufacturing,
commented that ‘The ARC®+ Simulator
allows students to acquire manual dexterity much faster and efficiently, a skill they
can then transfer to real welding with
confidence. This process improves our
training in a lot of ways.’
Simon Shaienks, Director of Business Development for 123 Certification
believes the company is the only one
with the flexibility to respond to complex
The Arc+ Welding Simulator is a
training tool that powers lifelike
virtual welding practice
The GSI SLV Welding Trainer combines elements of hands-on education of welders
and computer-based simulation to educate welders as realistically as possible
industry needs. ‘We are working toward
understanding and incorporating industry
specific application into our simulator, not
just basic welding training’ said Shaienks.
‘The uses are numerous and would bring a
lot of cost saving while improving quality
of welds. We are currently actively looking
for industry partners to participate and test
our future development.’
The next generation model of ARC®+
is designed so that customers can choose
the features that they need the most and
only pay for what they need. This ‘build
your own simulator’ concept will make
the use of the simulator applicable to
any type of training, ranging from the
most basic to the more advanced welding
courses. Minimal budgets, for example,
will have the opportunity to start with the
basic systems at a very affordable cost and
will be able to add new modules as their
training programs evolve.
The company sees IIW as an ambassador of the welding trade in general,
providing a forum where members can
bring their local challenges and express
them to an array of others from many
sectors and industries. The flow of ideas
that results from these discussions is
really extremely beneficial and makes
all participants grow. By spreading good
ideas and best practices, 123 Certification
believes the IIW is making a huge impact
in the world of welding.
‘We look forward to participate in the
new IIW Commission XIV Sub-committee
on welding simulation’ said Shaienks.
‘Welding simulation is now an integral
part of many training programs and we
are only scratching the potential of these
tools. We have a huge vision for our
welding simulators for the next 10 years
and we are happy to exchange ideas with
people that share an interest in that vision.’
Contact: Simon Shaienks
Email: [email protected]
20 AUSTRALASIAN WELDING JOURNAL – VOLUME 59, THIRD QUARTER – 2014
GSI SLV Welding Trainer
For decades the education of welders has
been performed consuming a lot of material, energy and time. The integration of
computer-based training systems offers a
modern approach to reduce the expenditure
of resources and to enhance education by
modern media and educational methods.
The GSI SLV Welding Trainer combines elements of hands-on education of
welders and computer-based simulation
to educate welders as realistically as
possible. Course participants learn basic
welding techniques while handling a real
arc with a minimum of amperage. All main
parameters are monitored by camera and a
computer-backed measuring system, and
any irregularity immediately signalled to
the welder. The use of the GSI SLV Welding Trainer requires minimal materials,
spare parts, electrical power and personal
protection and the education of welders
is faster and more efficient.
Currently 90 units of the GSI SLV
Welding Trainer are in use worldwide.
Principally the systems are used in vocational schools, training centres for welding
education and vocational training centres
of companies. They are also used for
education fairs promoting recruitment of
apprentices and in universities delivering
easy hands-on experience for students.
The system has evolved to supplement
traditional educational methods in a userfriendly way. Among other advances is the
development of an ‘intelligent educational
schedule’ and its integration to the teaching methods of this educational medium.
The fact is that the costs for the education of welders in the early stages of
training are reduced through the use of
virtual welding. The system delivers
‘just-in-time learning’ because the notice
of relevant handling errors takes place in
real time, allowing immediate correction
of technique.
Customers report 20 and 30 per cent
reduction in training costs and GSI SLV
is continuing to research in this area and
refine the technology.
‘The integration of an intelligent curriculum is completed and is state-of-theart’ reported Axel Börnert, Marketing
Manager of SLV Halle GmbH. ‘The next
step in development is to complete the
available welding processes for training
by the addition of MMAW. In the near
future we will have complete education
systems by using linked welding trainers
in separate classrooms with additional
e-learning. IT will be integrated. Distance
learning via internet may be possible’.
In terms of the use of the system in
developing countries, what these countries
need is fast recovery of the lost ground in
education. Börnert believes that modern
methods in education are helpful and
necessary to achieve this goal. Modern
training centres with modern equipment
are required, and computer-based welding
training systems are one of the basics.
By sharing information through IIW,
the value of such systems will become
widely known, and they can be assessed
and implemented where they will generate
the greatest benefit. As these new training
methods are being constantly developed
and improved, an organisation such as IIW
is ideal for enabling the rapid distribution
of information about current best practice.
Contact: Axel Börnert
Email: [email protected]
RealWeld Trainer
Patented by EWI and commercialised by
RealWeld Systems, Inc. the RealWeld
Trainer is a live arc welding training
solution invented in the USA to deliver
best practice applications in both the
education and manufacturing sectors.
Launched just eighteen months ago, the
device is enjoying traction and success in
North America with approximately 75%
of the deployments in schools and 25%
in manufacturing.
Manufacturers are deploying the
system as a screening tool for new-hires,
particularly to gauge the welder’s versatility in adjusting to different welds. They
are also deploying the system as a weld
procedure development tool by capturing
the technique of a master welder, configuring that captured technique into welding
procedures on RealWeld Trainer, and
thereby establishing a benchmark standard
for that master’s technique.
Schools appreciate that the system
provides more immediate feedback to
trainees before, during, and immediately
after welding. The system allows the
instructor to spend their precious one-onone time on teaching and inspiring rather
than mechanics. Unlike virtual reality simulators,
trainees weld live using standard welding machines and procedures, while the
RealWeld Trainer gives them real-time
feedback. They can also practice welding motions with the arc-off, still receiving feedback and developing consistent
technique, but with significant materials
savings.
Contact: Bill Forquer Email:
[email protected]
AUSTRALASIAN WELDING JOURNAL – VOLUME 59, THIRD QUARTER – 2014 21
WELDING TRAINING SYSTEMS
A welding class in the USA utilises the RealWeld Trainer to give real-time feedback
on live welding using standard welding machines and procedures, as well as
practice welding with the arc-off
Audio coaching during set-up, practice
motion and live welding is non-intrusive,
context specific and can be customised.
Feedback enables the student to make realtime corrections to technique. Quantitative
measurements during the live welding give
an ongoing record of progress which can
be monitored by instructors and used in
team building and group and competitive
learning.
The RealWeld Trainer helps prepare
‘job-ready’ welders by tailoring training
targets to optimum production procedures,
thus minimising the effects of transition
from training to the shop floor. Duplicating
target ranges for a given procedure ensures
all students learn the same technique
regardless of instructors, classes, locations
and time periods, meeting large industries’
need for consistent staff capabilities across
multiple work sites.
Current developments include the
expansion of skills training packages to
include broader learning objectives and
media, and the inclusion of pipe welding
training in the system.
Bill Forquer, Launch CEO for RealWeld
Systems, Inc. sees exciting future developments which will leverage cloud, webcamera and distance learning technologies.
‘Using these technologies, measurement and recording of skill achievements
and welding capabilities could evolve into
digital credentials for qualified welders,
where training organisations issue ‘digital
badges’ and cloud-based databases provide evidence of training completion and
acquired proficiency. Badges would be
authenticated by the issuer, included in
digital resume collections and tracked
over the welder’s entire career’ he said.
The availability of welders and quality of welding instruction those welders
receive is commonly cited as a bottleneck
in manufacturing in developing countries. Forquer revealed that ‘RealWeld plans
to develop a welding instruction kiosk
whereby the trainee can safely learn to
weld while their welding instruction is
delivered to them over the internet.’
‘We’re excited about these future
developments and the positive feedback we are receiving to our plans’ said
Forquer. ‘Certainly it is the role of IIW
and other welding societies to expose
their membership to all advancements in
welding education and training and we
look forward to future opportunities to
assist in that endeavour’. WELDING TRAINING SYSTEMS
Skill Digitiser™
Originally the Skill Digitiser™ was
designed to meet needs within Toshiba
Corporation in Japan, and five systems
are currently used in their Welder Training
Centre to cover a range of processes used
in production. Demand has since led to
three systems being sold to other company
training centres, and one is utilised at the
Japanese National College of Technology.
To establish the system, the techniques
of a skilled welder were first quantified and
digitised. A knowledge base was developed
from the real images and data and used as
the benchmark for welding training and
skill development of practical welders.
Numerical representation and digitisation of welding skill can be achieved by
the measurement of the welder’s motion,
using visual sensors in the system. The
first training system to be developed and
used was based on the visualisation of
GTAW skills used in welding the first
layer of flat plate.
The system is composed of four visual
sensors, a computer and a display. Features
of this system are digitisation, visualisation
and comparison with the welder’s welding
skill motion. While displaying time series
variations of seven measurement items, it
standardises as a skill index over 14 items,
the average values and variations, as well
as an evaluation result chart.
Satoru Asai, Chief Specialist, Keihin
Product Operations with Toshiba reported
‘it is possible to evaluate several skill
indices together with different dimensions
and helps give an intuitive indication of
the welder’s skill’.
The digitisation system has been developed for visualisation and digitisation of
Coming to Melbourne
in July 2016
Australian welding educators from
training providers and industry will
have the exciting opportunity to view
these systems and others first-hand,
and discuss their application with
the experts, during the IIW Annual
Assembly 10-15 July 2016 being
hosted by WTIA in Melbourne.
IIW Commission XIV will present
the outcomes of the ongoing evaluation
of such systems, as well as innovations
in the field of welder training, so mark
these dates in your diary now to secure
your attendance at this unique event.
Welding torch with fixed camera
Side view camera 2
Whole view camera
Gas nozzle
Side view camera 1
Fixture for test piece
CCD
camera
with
mirror
Welding wire
Measuring controller
Skill Digitiser™ setup for semi-automatic MAG welding
TIG root pass welding, semi-automatic
MAG welding of flat plate, all-position
TIG welding of pipe and MMAW.
The Skill Digitiser™ enables a quantitative evaluation, by image comparison,
which can be utilised effectively in the
early training period of skilled welders
and in their on-going skill development.
These systems show successful results in
actual training and also the pre-screening
and selection of skilled welders for specific
production welding tasks.
Contact: Satoru Asai
Email: [email protected]
Conclusion
The IIW Commission XIV review above
demonstrates that both welding simulation/
virtual welding and live weld monitoring
can deliver excellent outcomes for welder
training. They can augment current training methods and tackle on-going issues
common to countries around the world,
such as the cost of materials for training,
lack of facilities and skilled trainers, difficulties in standardising and recording
training and achievements, and the health
and safety of students.
22 AUSTRALASIAN WELDING JOURNAL – VOLUME 59, THIRD QUARTER – 2014
These modern training methods and
media also serve to make welding as a
career more attractive to younger generations. Not only do they gentrify the image
of welding and link with current trends
in electronic gaming and communication technologies, they also enable large
numbers of youngsters to ‘have a go’
at welding in a controlled environment
before committing to training. This in
turn should reduce attrition of students
and apprentices, and improve workforce
stability and forecasting for industry and
training bodies.
IIW Commission XIV has established a
Working Group to promote, and make more
accessible, the developments in welder
training that are continually taking place
around the world. The group will provide
a forum to discuss dovetailing such technologies with traditional training methods,
and explore the potentials for improved,
globally harmonised qualification and
certification of welding personnel.
This objective links with the broader
IIW project ‘to improve the global quality
of life through optimum use of welding
technology’.

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